Brick package and method of making same



Jan. 2, 1962 o. M. JONES BRICK PACKAGE AND METHOD OF MAKING SAME Filed April 4, 1955 INVENTOR. am /V Amer/Mu fax/6 Afro/awn? United States Patent Ofiice 3,015,192 Patented Jan. 2, 1962 3,015,192 BRICK PACKAGE AlglD METHOD OF MAKING Owen M. Jones, Seattle, Wash., assignor to vermiculite Manufacturing Co., Seattle, Wash, a corporation of Washington Filed Apr. 4, 1955, Ser. No. 499,842 2 Claims. (Cl. 50-103) The present invention relates to a brick of light weight and attractive appearance, and a method of making such a brick, as well as a wall constructed from such bricks.

An important object of the present invention is to provide an accurately constructed brick of light weight which can be used principally for interior walls and wall surfaces. Because of such lightwei ht no better foundation for such walls and wall surfaces is required than for wood walls. Not only are such bricks light, but they are made from material and of a construction which is very attractive in appearance. Moreover, the accuracy with which the bricks are made enables them to be bonded together to form a wall or wall facing, or to a backing surface to form a wall facing, by use of a thin coating of adhesive and without the use of mortar. When they are to be used as a wall facing the bricks can be made quite narrow to save space and material.

' Another object is to enable a wall to be fabricated from such bricks which will be fire resistant, durable, sound absorbent and will have considerable thermal insulating value.

In the method of making such .bricks it is an object to utilize techniques which will enable the bricks to be made economically in quantity production and to be packaged, stored and shipped easily and without damage to the bricks. Sales outlets for such bricks can be more diversified than for conventional bricks, including not only lumber and building material dealers but department stores, paint stores and mail order houses. In such manufacture it is a further object to produce such bricks in plural units and to divide such units into bricks. In this procedure it is an object to score a double brick unit in a manner which will establish an approximate location of fracture between two bricks. The broken surface of each brickwill provide an attractive, rough appearance over most .of the area of the surface to be exposed and a chamfered border around such rough surface forming a pattern or simulating a mortar joint when the bricks have been laid up as a wall. I 1

In the production of such bricks it is an object to incorporate in the mixture from which they are formed material which will have an attractive sheen in the fractured rough surface of the brick exposed when the bricks are laid up, giving unusual life and character to the wall. Pigment can be included in the mix to provide any of a variety of colors for the bricks.

"The foregoing objects can be accomplished by molding double brick units from a mixture of Portland cement and aggregate, in whichthe aggregate includes a subs-tantial amount of fine, heateexpanded vermiculite, which is a micaceous material, and such coloring pigment as may be desired. The double brick unit is provided with a groove encircling it generally centrally, either by using a mold box which will form the groove during molding of the unit, ,or by scoring the unit when the material has set. In either case after the unit has set it may be supported at one side at the location of such groove, and pressure can be applied to the opposite side at locations spaced from the groove to fracture the double unit into two bricks. When such fracture has occurred, however, the fractured surfaces are moved into contiguous engagement without displacement. The bricks will be held in this relationship during packaging and shipment, so that when they are ready for use the rough surfaces resulting from the fracture will have clean, relatively sharp ridges and peaks which have not been abraded or defaced by handling or shipment. The fractured surface will expose broken surfaces of particles of the vermiculite aggregate which produce a sheen much more pronounced than in other surfaces of the brick.

FIG. 1 is a top perspective view of bricks boxed in accordance with the present invention with parts broken away, and

FIG. 2 is a transverse sectional view through the brick package.

The present product fills the need for a decorative, lightweight, durable wall facing which can be used to cover any wall surface whether of plaster, concrete, wood or open construction, such as stripping or grilling. Moreover, it is important that such bricks be capable of satisfactory use to build or face a wall by an unskilled person, while the resulting wall surface will have the appearance of a professional job.

In order to obtain the desired fractured surface for exposure in a wall constructed of bricks of the present invention, it is necessary that the bricks 1 and 2 shown in the drawings be formed initially in plural brick units, each unit preferably being of a size and shape to produce two bricks. Such a double brick unit can, of course, be of a shape and dimensions to produce bricks of any desired length, width and thickness within reasonable limits. Because wall facings for which bricks of the present invention will be used will not be expected to sup port any appreciable load, the horizontal thickness of the bricks as they are laid in a wall can be quite small so long as such thickness is adequate to provide a stable support for the upper brick courses when backed by a wall. A horizontal thickness which has been found to be satisfactory is one and three-eighths inches. Preferably the vertical width is one and one-half inches, or multiples thereof, but a different increment, larger or smaller, may be selected. The length of each brick also may be selected from a considerable range of lengths, such as from six inches to twenty-four inches.

If double brick units are to be produced from which two bricks 1 and 2 will be made, the width of such a double brick unit will be two and threequarter inches if the horizontal width of each final brick is to be one and three-eighths inches. The other dimensions of the double brick unit will correspond directly to the vertical width and the length of the surface of a finished brick which is to be exposed. Such double brick units may be made by mixing the various ingredients and placing the resulting mix in a mold of appropriate dimensions to set. The mix will be of the Portland cement and aggregate type andmay incorporate such pigment material or setting agents as needed. An essential aggregate ingredient, however, is heat-expanded vermiculite. The particles of such vermiculite should be of a size such that at least 90 percent of the vermiculite, by volume, will pass a standard 14- mesh screen, and it is preferred that all of the vermiculite be able to pass a 20-mesh screen, but the incorporation of some larger particles is not objectionable.

While the vermiculite can constitute the entire aggregate to be mixed with the Portland cement, the resulting brick would be too soft and light. To obtain higher strength values, fine aggregate other than vermiculite','such as sand, expanded shale, diatomaceous earth, etc. should be used in conjunction with the vermiculite. By volume, fine vermiculite may. constitute from 30 percent to percent of the aggregate, in a preferred mix approximately half of the aggregate, by volume, being vermiculite. The Portland cement, aggregate and water may be mixed together in conventional manner in a mechanical concrete mixer. To the water may be added a suitable air entraining agent, an accelerator, and a waterproofing agent if desired. The mixture is vibrated in molds and allowed to set sufficiently to enable the mold to be removed. The final set of the mixture can take place by allowing-the molded units simply to stand on pallets, but the set canbe expedited by placing the units in a steam room. After the units have set for approximately three days at normal temperatures, or for approximately eight hours in a steam room, they may be dried in a kiln for a period of eight to twelvehours at a temperature of 150 F. to '225' F. i

As has been mentioned, the incorporation of heat expanded vermiculite in the aggregate will produce a surface which sparkles in a fractured surface of the product. Consequently it is desired to make provision for breaking a double brick unit to provide two bricks each having a fractured surface to be exposed when the bricks are laid up. Because it is desired that the finished wall surface have a decoratively rough appearance it is not necessary that the horizontal thickness of the double brick unit be preeise. Q It is essential, however, that the molds and molding technique used in producing the double brick units form the vertical width dimension very exactly, such as within a tolerance of plus or minus 0.01 of an inch. This Will insure that the upper and lower edges of the brick will be exactly parallelwithin such tolerance, and the vertical width'of each brick willbe the same as the vertical Width of each other brick within such tolerance. Such control of brick vertical width will enable the bricks to be bonded together in a wall by the use of a thin coating of adhesive between them, such as A of an inch or less in thickness. Because the adhesive joint between adjacent bricks is so thin, it would be almost invisible at any appreciable distance from the wall. Usually it will be preferred, however, for the wall surface to have a pattern generally similar to that of a conventional brick and mortar wall. For that reason it is preferred to provide around the exposed rough face surface of each brick a charnfered border 3such that adjoining borders of adjacent bricks will give theappearance of..a mortar joint or pattern between them. Such appearance results from the contrast between the smooth character of the chamfered surface and the rough character of the fractured, exposed face within the chamfered border. This chamfered border around the exposed face of a finished brick may be formed by cutting a groove around the center of the double brick unit in a median plane extending lengthwise of the double brick unit and perpendicular to its upper and lower faces. Alternatively, such a groove may be molded in the unit while it is being formed.

After the double brick unit of the type described above has set and been dried, it may be broken at 4 generally in the plane of the groove into the two brick units 1 and 2 with rough fractured face surfaces. The rather sharp ridges and points of such a fractured surface produce an attractive decorative effect. Consequently, it is desirable to protect such faces from abrasion or mutilation prior to use of the bricks. Bricks made in accordance with the present invention are quite light, so that it is practical to ship them for considerable distances, making damage to the face surfaces more probable. On the other hand, particularly because the bricks are quite narrow, it is not practical'to break them easily and with accuracy just prior to use, and in particular an unskilled person would experience difficulty in breaking the bricks properly.

Consequently, it is preferred that the double brick units be broken into their two parts 1 and 2 prior to delivery or shipment. The breaking operation is accomplished by engaging in a groove along one side of the unit a rib slightly narrower than such groove and applying force against the opposite side of the unit at locations equally spaced asubstantial distance from the groove in such other side. Movement of the pressure exerting members can be limited so that upon being broken the portions of the fractured surfaces remote from the rib will separate only a small fraction of an inch, such as from A to of an inch. Such movement Will insure complete fracture of the double brick unit at the location of the groove because the material is sufficiently brittle when set.

The two parts 1 and 2 of the block thus broken, instead of being separated farther, may immediately be moved toward each other to fit together the fractured surfaces of the two bricks in intimate, contiguous, matching engagement. In this relationship the bricks can be boxed as shown in the drawing or wrapped in a manner to prevent relative shifting of the bricks, the fractured surfaces of the two bricks 1 and 2 thus being mutually protected until the bricks are ready for use. I

While the provision of a groove around the double brick unit assists decidedly in establishing with reasonable accuracy the location of the fracture between the two bricks to be formed from such "a unit, the depth 'of the groove is not at all critical. The groove depth and cross-sectional shape maybe selected, therefore,'depend ingup'on the type of appearance desired,which will'be governed to some extent by the vertical width of the bricks. The particular cross-section of the groove se lected may produce a charnfered border aIo'undthe fac'e of the finished brick of fiat'beveledshape, of concave shape, or of inclined convex' shape, as may bap're: ferred. The desired shape of chamfered edge canbe controlled readily by selecting an appropriate "cone: sponding shape of grooving cutter periphery, if the groove is formed as'an abrasive cutting wheel kerf, or by shaping the mold box rib appropriately if the groove is molded into the double brick unit. A

' While the brick of the present invention is capable of carrying some load and is reasonably resistant to; abrasion, it is intended primarily for use indoors where it will be protected from the weather. Such a brick, however, is suitable for exterior use because it will net deteriorate appreciably from changes in moisture content e'ven' 'though it may be subjected to direct'impact by rain for an extended period, or to being wet'and dried successively. "Moreover, the brick will not'beinjured by being successively fro'zenand thawed even when quite wet. Whethe'r'the brick is used inside or outside, however, it will usually be used as a facing for a backing wall, which may be of plaster, concrete," wnod," metal, etc.

While the bricks can be secured together by the use of moi-tar in accordance with conventional brick-'1 laying technique, a wall facing may be constructed from themmuch more simply falthough entirely practically; by securing the bricks'in place' with adhesive. able adhesive is that of the general type used for setting ceramic tile. A very thin coating of such glue or'ad hesive can be used, such as A.; of an inch or' less in thickness." If the wall is constructed outdoors, the adhesive'should, of course, be of a water-resistant or Water proof type. "Such adhesive may be used between the upper and lower faces of successive courses of bricks to secure the superposed brickstogether, or the adhesive could be used to, bond the back surface of each brick to the backing wall, or adhesive could be used at bothlm cations.

Use of adhesive to secure the bricks of the present invention ina wall facing as distinguished'frorn' using mortar, has several important advantages. When mor tar is used it is necessary that the comparatively thick mortar bond be of approximately uniform thicknessin orderto produce a wall of attractive appearance. Itis difficult for an unskilled person to apply such'a uniform layer of mortar, and invariably the mortar is smeared over the decorative face of the brick'and is hard to clean off. Mortar usually also will be dropped on the floor, which'r'nust be cleaned up. Adhesive of the type specified, however, can simply be applied with a putty knife, andfas a practical matter, the; thickness of the ad hesive coating applied can scarcely vary enough to alter the appearance of the wall. To make use of such adhesive practical, however, it is essential that the vertical width of the bricks be accurate to the degree stated above.

Another advantage of adhesive over mortar is that the adhesive can be purchased in a can ready for use, whereas mortar ordinarily must be mixed. In any event, the quantity of mortar required would far exceed the amount of adhesive needed, so that it is relatively dithcult to handle mortar, as well as mortar being much slower to apply. The adhesive can be stored easily for a long period so that work can be resumed on a wall at any time, and many or few bricks can be laid in any particular stretch. Where mortar is used, however, it takes considerably longer to organize for work and to clean up after work is completed or interrupted for a time.

Because of the manufacture of the bricks to exact vertical width dimensions and the negligible thickness of the bonding layer between the bricks, an unskilled person can maintain the courses level and straight without difficulty, whereas he could not if conventional mortar were used in the joints. It is possible to use an adhesive instead of mortar successfully, however, because of the light weight of the bricks and the smooth and true character of the surfaces which are bonded. While, as has been discussed, it is preferred that the bricks be produced by molding a two brick block so that such surfaces would be formed simply by setting in contact with a. smooth mold, satisfactory surfaces for adhesive bonding could be produced by molding the material in larger units and cutting them to the desired size by the use of an abrasive wheel.

The resulting wall made from the lightweight bricks described secured in place with adhesive will have a very decorative effect such as in finishing a basement having walls of poured concrete. The brick wall also will have substantial insulating value. Whether or not the bricks are colored, the specks or flecks of vermiculite in the fractured face surfaces of the bricks will sparkle, affording a very attractive wall surface.

in set condition the material of which the bricks are made preferably weighs between 51 /2 and 71 pounds per cubic foot, so that in a wall facing using bricks 1% inches thick the weight per square foot of wall surface would be 6 to 7 pounds. Thus the specific gravity of the set bricks would range from 0.8 to 1.1.

Such specific gravity can be changed by altering the mix used. The aggregate in a brick having a specific gravity of 0.8 might be 40 percent heat-expanded shale and 60 percent heat-expanded vermiculite, while the aggregate in a brick having a specific gravity of 1.1 might be percent heat-expanded shale and 30 percent heat-expanded vermiculite. In both cases approximately 25 pounds of Portland cement per cubic foot of aggregate is used. The cement content might be selected from 15 pounds to 30 pounds per cubic foot.

The weight per running foot of a wall facing eight feet high made from bricks in the range of specific gravity mentioned would be 48 to 56 pounds. The bricks in a brick facing of this weight could be bonded by adhesive directly to the face of a wall backing, or the bricks could be supported on the floor alongside a wall face to be covered without any special provision for foundation. Such bricks, therefore, are quite suitable for use in remodeling upper story wall surfaces of a frame building construction.

Another advantage to the lightweight bricks of the present invention is that they are soft enough so that they can be cut with a pocket knife, a hack saw, or even an ordinary carpenters saw of the type used for cutting wood. No special dexterity or technique is required, therefore, to cut the bricks to any desired shape as is required in shaping burned clay bricks.

I claim as my invention:

1. The method of supplying bricks which comprises providing a double brick unit of molded material incorporating heat-expanded micaceous material aggregate, breaking such unit into two bricks and thereby fracturing particles of such heat-expanded micaceous material aggregate, fitting such fractured surfaces together in intimate, contiguous, matching engagement, and boxing such bricks in a manner maintaining such fractured surfaces immobilized against shifting relative to each other in such matching engagement.

2. A brick package comprising two bricks incorporating heat-expanded micaceous material aggregate and having complemental fractured faces revealing fractured surfaces of such micaceous material, and box means holding said bricks together in immobile relationship with their complemental fractured faces in intimate, contiguous, matching engagement.

References Cited in the file of this patent UNITED STATES PATENTS 379,429 Werth Mar. 13, 1888 1,534,353 Bcsser Apr. 21, 1925 1,859,539 Slidell May 24, 1932 1,872,522 Stuckey Aug. 16, 1932 1,880,897 Drewsen Oct. 4, 1932 2,007,808 McElroy July 9, 1935 2,124,759 Bradbyer July 26, 1938 2,250,319 Wright July 22, 1941 2,476,433 Shinn July 19, 1949 

2. A BRICK PACKAGE COMPRISING TWO BRICKS INCORPORATING HEAT-EXPANDED MICACEOUS MATERIAL AGGREGATE AND HAVING COMPLEMENTAL FRACTURED FACES REVEALING FRACTURED SURFACES OF SUCH MICACEOUS MATERIAL, AND BOX MEANS HOLDING SAID BRICKS TOGETHER IN IMMOBILE RELATIONSHIP WITH THEIR COMPLEMENTAL FRACTURED FACES IN INTIMATE, CONTIGUOUS MATCHING ENGAGEMENT. 